Method for producing dustless graphite spheres from waste graphite fines

Abstract

A method for producing graphite spheres from graphite fines by charging a quantity of spherical media into a rotatable cylindrical overcoater, charging a quantity of graphite fines into the overcoater thereby forming a first mixture of spherical media and graphite fines, rotating the overcoater at a speed such that the first mixture climbs the wall of the overcoater before rolling back down to the bottom thereby forming a second mixture of spherical media, graphite fines, and graphite spheres, removing the second mixture from the overcoater, sieving the second mixture to separate graphite spheres, charging the first mixture back into the overcoater, charging an additional quantity of graphite fines into the overcoater, adjusting processing parameters like overcoater dimensions, graphite fines charge, overcoater rotation speed, overcoater angle of rotation, and overcoater time of rotation, before repeating the steps until graphite fines are converted to graphite spheres.

1. A method for producing graphite spheres, wherein the graphite spheres consist of graphite, the method, comprising the steps of collecting a waste mixture consisting essentially of waste graphite fines, placing said waste mixture into a vessel, and rotating the vessel containing the mixture consisting essentially of waste graphite fines to form graphite spheres. 
     
     
       2. The method according to  claim 1 , wherein the vessel is a rotatable cylindrical overcoater and the method further comprises adjusting at least one processing parameter selected from the group consisting of overcoater dimensions, waste graphite fines charge, overcoater rotation speed, overcoater angle of rotation, and overcoater time of rotation. 
     
     
       3. The method according to  claim 1 , wherein the graphite spheres are dustless graphite spheres. 
     
     
       4. A method for producing graphite spheres from graphite fines, wherein the graphite spheres consist of graphite, the method comprising the steps of:
 a) charging a quantity of spherical media into a rotatable cylindrical overcoater, 
 b) charging a quantity of waste graphite fines into said rotatable cylindrical overcoater thereby forming a first mixture of said spherical media and waste graphite fines, 
 c) rotating said rotatable cylindrical overcoater at a speed such that said first mixture climbs the wall of said overcoater before rolling back down to the bottom thereby forming a second mixture of spherical media, waste graphite fines, and graphite spheres, 
 d) removing said second mixture from said overcoater, 
 e) sieving said second mixture to separate said graphite spheres from said second mixture, thereby leaving said first mixture, 
 f) charging said first mixture back into said overcoater, 
 g) charging an additional quantity of waste graphite fines into said overcoater having said first mixture, 
 h) adjusting at least one processing parameter selected from the group consisting of overcoater dimensions, waste graphite fines charge, overcoater rotation speed, overcoater angle of rotation, and overcoater time of rotation, 
 i) repeating steps b) through h) until waste graphite fines are converted to graphite spheres. 
 
     
     
       5. The method of  claim 4  wherein said spherical media further comprises zirconia and pyrolytic carbon. 
     
     
       6. The method of  claim 4  wherein said rotatable cylindrical overcoater is made from at least one material selected from the group consisting of metal and plastic. 
     
     
       7. The method of  claim 4  wherein the particle size of said waste graphite fines is in the range of approximately 6 to 12 microns. 
     
     
       8. The method of  claim 4  wherein said waste graphite fines charge is in the range of approximately 0.1 to 20 grams. 
     
     
       9. The method of  claim 4  wherein said overcoater rotation speed is in the range of approximately 0.1 to 20 RPM. 
     
     
       10. The method of  claim 4  wherein said overcoater angle of rotation is in the range of approximately 10 to 80 degrees. 
     
     
       11. The method of  claim 4  wherein said overcoater time of rotation is in the range of approximately 0.1 to 30 minutes. 
     
     
       12. The method of  claim 4  wherein said graphite spheres are in the range of approximately 50 to 5000 microns. 
     
     
       13. The method of  claim 4 , wherein the graphite spheres are dustless.